Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
  • B29D99/00—Subject matter not provided for in other groups of this subclass
  • B29D99/0025—Producing blades or the like, e.g. blades for turbines, propellers, or wings
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
  • B32B25/04—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B25/08—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
  • B32B25/10—Layered products comprising a layer of natural or synthetic rubber next to a fibrous or filamentary layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
  • B32B25/14—Layered products comprising a layer of natural or synthetic rubber comprising synthetic rubber copolymers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
  • B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
  • B32B27/322—Layered products comprising a layer of synthetic resin comprising polyolefins comprising halogenated polyolefins, e.g. PTFE
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
  • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
  • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B38/00—Ancillary operations in connection with laminating processes
  • B32B38/18—Handling of layers or the laminate
  • B32B38/1866—Handling of layers or the laminate conforming the layers or laminate to a convex or concave profile
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
  • C09J163/00—Adhesives based on epoxy resins; Adhesives based on derivatives of epoxy resins
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
  • C09J175/00—Adhesives based on polyureas or polyurethanes; Adhesives based on derivatives of such polymers
  • C09J175/04—Polyurethanes
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
  • F03D—WIND MOTORS
  • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
  • F03D1/06—Rotors
  • F03D1/065—Rotors characterised by their construction elements
  • F03D1/0675—Rotors characterised by their construction elements of the blades
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
  • B32B2260/02—Composition of the impregnated, bonded or embedded layer
  • B32B2260/021—Fibrous or filamentary layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
  • B32B2260/04—Impregnation, embedding, or binder material
  • B32B2260/046—Synthetic resin
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/02—Synthetic macromolecular fibres
  • B32B2262/0253—Polyolefin fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/10—Inorganic fibres
  • B32B2262/101—Glass fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/10—Inorganic fibres
  • B32B2262/106—Carbon fibres, e.g. graphite fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2274/00—Thermoplastic elastomer material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2603/00—Vanes, blades, propellers, rotors with blades
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
  • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
  • F05B2280/00—Materials; Properties thereof
  • F05B2280/40—Organic materials
  • F05B2280/4003—Synthetic polymers, e.g. plastics
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E10/00—Energy generation through renewable energy sources
  • Y02E10/70—Wind energy
  • Y02E10/72—Wind turbines with rotation axis in wind direction

Definitions

• the present invention relates to a composite component, the use of a composite component according to the invention, a wind turbine for a wind turbine and a method for producing a composite component.
• Rotor blades for wind turbines have long been known and described for example in DE 10 2004 007 487 A1 and DE 10 319 246 A1. They are exposed in their operation by wind pressure, erosion, temperature fluctuations, UV radiation and precipitation high loads. Especially in locations with tropical climates, which are characterized by strongly changing weather conditions and high humidity, such as Brazil or Taiwan, but also in Germany rotor blades tend to erosion.
• rotor blades and rotor blade elements are produced in a molding process in which fiber materials and / or core materials, in particular balsa wood, are inserted into a rotor blade element mold and subjected to a hardening resin for forming a resilient composite material.
• Epoxy resins are often used as the resin in the manufacture of rotor blades or rotor blade elements. These are well suited for the construction of the base of a rotor blade or rotor blade element of fiber material and resin.
• UHMW-PE ultrahigh molecular weight polyethylene
• UHMW-PE is characterized by very good wear and abrasion resistance even with abrasive media. Its abrasion resistance is six times higher than that of polyurethane.
• UHMW-PE has excellent chemical resistance. and a low coefficient of friction, excellent dimensional stability and high impact resistance even at low temperatures.
• UHMW-PE is very difficult to bond with conventional adhesives and in particular does not adhere to resins, such as epoxy resins.
• the polyethylene film is therefore connected by means of two bonding layers made of rubber to an underlying base made of a hardened resin impregnated fiber material.
• a total of three hardening or vulcanization steps are necessary in order to coat a rotor blade element.
• the plastic composite component described in WO 2010/1 18860 consists of a thermosetting synthetic resin as an outer layer, an elastomeric layer and a metal and / or plastic carrier layer. The layers are combined in a single operation under heat treatment or under irradiation with UV light.
• the use of the plastic composite component in rotor blades of helicopters or wind turbines is described in WO 2010/1 18860.
• Object of the present invention was to provide a component, in particular a rotor blade, which is characterized by a very high wear and abrasion resistance and at the same time requires little time and low temperatures in the production.
• a composite component (10) which is characterized by the following layer structure a) a layer (1 1) which consists at least partially of polyethylene, b) a layer (12) at least partially made of a polyurethane and / or elastomer is, c) at least one layer (13) which consists at least partially of a plastic (14) reinforced plastic, or at least partially consists of an adhesive, wherein the layer (12) directly between the layer (1 1) and the layer (13) is arranged, wherein the layers (1 1) and (12) were joined in a first operation to a laminate composite and the layer (13) were joined in a second operation to the laminates comprising the layers (1 1) and (12).
• the phrase that the layer consists at least in part of a "polyurethane and an elastomer” means that the designated material is also a polyurethane elastomer.
• polyurethane or elastomer means in that it refers to either a non-elastomeric polyurethane or an elastomer which is not a urethane elastomer.
• Preferred polyurethane in the present context is a thermoplastic polyurethane.
• the temperature required for joining can be kept lower than would be the case if the polyurethane layer (12) or the elastomer layer (12) also had to be cured.
• a simplification and acceleration of the joining is achieved as a significant advantage.
• the adhesion of the individual layers is increased.
• the polyethylene is a High Molecular Polyethylene (HMW-PE), an Ultra High Molecular Polyethylene (UHMW-PE) or polytetrafluoroethylene (PTFE), preferably an Ultra High Molecular Polyethylene (UHMW -PE).
• HMW-PE High Molecular Polyethylene
• UHMW-PE Ultra High Molecular Polyethylene
• PTFE polytetrafluoroethylene
• the Ultra High Molecular Polyethylene (UHMW-PE) is characterized by very good wear and abrasion resistance even with abrasive media.
• UHMW-PE Ultra High Molecular Polyethylene
• a high molecular weight polyethylene is understood as meaning a high molecular weight polyethylene having an average molecular weight of 500 to 1000 kg / mol.
• UHMW-PE Ultra High Molecular Polyethylene
• the UHMW-PE used has an average molar mass between 1000 kg / mol to 10000 kg / mol, more preferably an average molar mass between 1000 kg / mol and 5000 kg / mol, particularly preferably between 3000 kg / mol and 5000 kg / mol.
• the determination of the average molecular weight is done mathematically by means of the Margolies equation.
• the polyethylene used may be a linear or a cross-linked polyethylene.
• the ultra-high molecular weight polyethylene used preferably has a density of 0.93 to 0.94 g / cm 3 .
• the layer (11) additionally contains a UV stabilizer which protects the polyethylene against aging by ultraviolet light.
• Preferred UV stabilizers are organic and inorganic UV absorbers, in particular those selected from the list comprising benzophenones, benzotriazoles, oxalanilides, phenyltriazines, carbon black, titanium dioxide, iron oxide pigments and zinc oxide or 2,2,6,6-tetramethylpiperidine derivatives such as bis (2.2 6,6-tetramethyl-4-piperidyl) sebacate ("hindered amine light stabilizer (HALS)").
• HALS hinderetramethyl-4-piperidyl
• the layer (1 1) which consists at least partially of polyethylene, consists predominantly of polyethylene, in particular more than 50 wt .-%, preferably more than 80 wt .-%, particularly preferably more than 95 wt .-% consists of polyethylene, in particular Ultra High Molecular Polyethylene (UHMW-PE), based on the total weight of the layer.
• UHMW-PE Ultra High Molecular Polyethylene
• a polyurethane is understood to mean a polyaddition product of at least dialcohols (dioxides) or polyols (for example long-chain dioxides) with polyisocyanates to form urethane groups (-NH-CO-O-).
• the elastomer be an ethylene-propylene rubber (EPM), ethylene-propylene-diene rubber (EPDM), ethylene-acrylate rubber (EAM), fluorocarbon rubber (FK), acrylate rubber (ACM). or acrylonitrile-butadiene rubber (NBR), preferably an ethylene-propylene-diene rubber (EPDM).
• EPM ethylene-propylene rubber
• EPDM ethylene-propylene-diene rubber
• EAM ethylene-acrylate rubber
• FK fluorocarbon rubber
• ACM acrylate rubber
• NBR acrylonitrile-butadiene rubber
• EPDM ethylene-propylene-diene rubber
• polyurethanes and elastomers in particular the preferred a particularly good bond between the layer (1 1), which consists at least partially of polyethylene, and the layer (13) effect.
• polyurethane and ethylene-propylene-diene rubber EPDM
• EPDM ethylene-propylene-diene rubber
• UHMW-PE Ultra High Molecular Polyethylene
• the polyurethane is a thermoplastic polyurethane.
• thermoplastic polyurethane is understood as meaning a polyurethane which can be reversibly deformed (thermoplastic) in a specific temperature range.
• thermoplastic polyurethanes in particular thermosetting polyurethanes are to be distinguished, which can no longer be thermoformed after curing.
• the polyurethane is a polyurethane elastomer.
• a polyurethane elastomer is understood as meaning a polyurethane which is elastically deformable and preferably has a wash temperature (Tg) (determined by means of differential scanning calorimetry (DSC) at a heating rate of 10 K / min) of not more than 20 ° C have.
• Tg wash temperature
• DSC differential scanning calorimetry
• the polyurethane elastomer has a glass transition temperature T g between -5 ° C and -45 ° C (determined by differential scanning calorimetry (DSC) at a heating rate of 10 K / min). It is preferred according to the invention if the polyurethane elastomer has a Shore A hardness according to DIN ISO 7619-1 of not more than 95, preferably of not more than 85, more preferably of not more than 75.
• the polyurethane elastomer has a Shore A hardness according to DIN ISO 7619-1 of more than 40, preferably more than 50, more preferably more than 60.
• the polyurethane elastomer has a Shore A hardness according to DIN ISO 7619-1 in the range of 40 to 95, preferably in the range of 50 to 85, more preferably in the range of 60 to 75.
• thermoplastic polyurethane elastomers with the abovementioned Shore A hardness values or ranges (in accordance with DIN ISO 7619-1) have particularly good properties when using the plastic composite component in rotor blades of helicopters or wind wheels according to the invention ,
• thermoplastic polyurethane is a condensation product of a polyol (long-chain diol) (preferably a polyester diol or polyether diol), a diisocyanate and a short-chain diol.
• a polyol long-chain diol
• a diol having a molecular weight of a short-chain diol Under a long-chain diol understood a diol having a molecular weight of 500 g / mol or more, preferably up to 8,000 g / mol understood.
• the combination of polyurethane (preferably thermoplastic polyurethane and / or polyurethane elastomer) in the layer (12) and Ultra High Molecular Polyethylene (UHMW-PE) in the layer (11) is characterized by particularly good erosion properties .
• the polyurethane elastomer layer (12) acts adhesion while the outer UHMW-PE layer (1 1) is very erosion resistant.
• the combination of ethylene-propylene-diene rubber (EPDM) in the layer (12) and ultra high molecular weight polyethylene (UHMW-PE) in the layer (11) is also characterized by particularly good Characterized erosion properties.
• the layer (12) is arranged directly between the layer (1 1) and the layer (13) and there are no further (polymer) layers between the layer (1 1) and the layer (13).
• EPDM ethylene-propylene-diene rubber
• UHMW-PE Ultra High Molecular Polyethylene
• the layer (12) is arranged directly between the layer (1 1) and the layer (13) and there are no further (polymer) layers between the layer (1 1) and the layer (13).
• the number of boundary layers can be minimized and improved adhesion of the layers is obtained.
• composite components according to the invention with only one layer (12) can be distinguished from other composite components which contain multiple (polymer) layers.
• composite components according to the invention can be distinguished from non-inventive components in which not first a laminate composite of the layers (1 1) and (12) and in a further second operation, the layer (13) in one of the layers (1 1) and (12) laminating composite were added. This is possible, in particular, by viewing the boundary layers, in particular the boundary layer between the layers (12) and (13).
• the layer (12) which consists at least partially of a polyurethane (preferably thermoplastic polyurethane and / or polyurethane elastomer), consists predominantly of polyurethane, in particular more than 50 wt .-%, preferably more than 80 wt .-%, more preferably more than 95% by weight of polyurethane, based on the total weight of the layer.
• a polyurethane preferably thermoplastic polyurethane and / or polyurethane elastomer
• the layer (12), which consists at least partially of an elastomer, consists predominantly of elastomer, in particular more than 50 wt .-%, preferably more than 80 wt .-%, particularly preferably more than 95 wt .-% consists of elastomer, in particular of ethylene-propylene-diene rubber (EPDM), based on the total weight of the layer.
• EPDM ethylene-propylene-diene rubber
• the layer (12) additionally contains at least one additive selected from the group consisting of acrylates. Methacrylates, epoxy resins, phenolic resins, novolaks, hexamethylenetetramine, hexamethoxymethylmelamine and guanidines. These additives are particularly preferred when the elastomer of layer (12) is an ethylene-propylene-diene rubber (EPDM). These additives are suitable for improving the strength of the layer (12) and / or improving the adhesion of the layer (12) to the other layers.
• EPDM ethylene-propylene-diene rubber
• the plastic reinforced by fibers (14) is a plastic reinforced by UHMW-PE fibers (eg Dyneema fibers), a carbon fiber reinforced plastic (CFRP) or a glass fiber reinforced plastic (GRP), preferably a glass fiber reinforced plastic (GRP).
• UHMW-PE fibers eg Dyneema fibers
• CFRP carbon fiber reinforced plastic
• GPP glass fiber reinforced plastic
• Fiber-reinforced plastics and especially glass fiber reinforced plastics (GRP) are characterized by high mechanical and thermal stability at a low specific weight and are therefore very well suited for the construction of the base of a rotor blade or rotor blade element.
• a composite component in which the plastic reinforced by fibers (14) is a plastic resin system with an epoxy resin matrix, polyurethane resin matrix, polymethyl (meth) acrylate matrix, poly (meth) acrylate matrix or poly (meth) acrylamide Matrix is, in particular preferably a Kunststoffharzsys- tem with an epoxy resin matrix.
• a composite component in which the plastic reinforced by fibers (14) is a plastic resin system with an epoxy resin matrix is preferred and the layer (13) additionally contains at least one additive selected from the group consisting of acrylates, methacrylates, phenol resins and novolaks ,
• the plastic reinforced by fibers (14) is a plastic matrix system having an epoxy resin matrix which before curing is present as a multicomponent system and at least one component comprising an amine curing agent, additionally at least one additive selected from the list consisting of hexamethylenetetramine, hexamethoxymethylmelamine and guanidines.
• the layer (1 1) and / or layer (12) independently of one another has a thickness of 100 to 5000 ⁇ , preferably a thickness of 300 to 900 ⁇ , more preferably a thickness of 400 to 600 ⁇ having.
• the laminate composite comprising the layers (11) and (12) has notches on the surface which is joined to the layer (13) in the second operation. The notches increase the area of the surface and increase the adhesion of the layer (13) to the laminate composite after joining in the second operation.
• the dialcohols (diols) or polyols (eg long-chain diols) are reacted with the polyisocyanates to give the polyurethane and those for the Reaction used catalysts are reacted or inactive.
• the laminate composite comprising layers (11) and (12) contains less than 0.5 pph (parts per hundred of catalyst per hundred parts polyurethane) (active) catalyst, preferably less as 0.2 pph (active) catalyst, most preferably no (active) catalyst.
• the laminate composite comprising layers (11) and (12) contains less than 0.5 pph (parts per hundred crosslinker per hundred parts elastomer) crosslinker, preferably less than 0.2 pph crosslinker, most preferably contains no crosslinker.
• the joining of the layer (13) to the laminates comprising the layers (11) and (12) takes place with the layer (13) curing.
• the at least partially made of a plastic reinforced by fibers (14) after assembly with the layers (1 1) and (12) comprehensive laminate composite is cured, for example by adding a curing agent shortly before joining or by the plastic with Light is irradiated, if it is a light-curing plastic.
• the plastic matrix of reinforced by means of fibers (14) plastic is prepared shortly before assembly by mixing a two-component mixture.
• the joining of the layer (13) to the laminates comprising the layers (1 1) and (12) takes place under the effect of heat, preferably at temperatures of at least 20 ° C., preferably of at least 35 ° C., more preferably of at least 55 ° C, more preferably of at least 75 ° C, if the layer (12) contains polyurethane.
• the joining of the layer (13) on the layers (1 1) and (12) comprising laminate composite under heat preferably at temperatures of at most 120 ° C, preferably of at most 1 10 ° C, on preferably of not more than 95 ° C., more preferably of not more than 85 ° C., if the layer (12) contains polyurethane.
• the joining of the layer (13) to the layers (1 1) and (12) comprising laminate composite under heat preferably at temperatures of 20 to 120 ° C, more preferably at temperatures of 35 to 1 10 ° C, more preferably at temperatures of 55 to 95 ° C and most preferably at temperatures of 75 ° C to 85 ° C, if the layer contains polyurethane.
• the joining of the layer (13) to the layers (1 1) and (12) comprising laminate composite under heat preferably at temperatures of 70 to 120 ° C, more preferably at temperatures of 80 to 1 15 ° C and most preferably at temperatures of 105 ° C to 1 15 ° C, if the layer (12) contains an elastomer.
• the composite component is designed so that the layer (13) consists at least partially of an adhesive and this adhesive is an epoxy resin adhesive or comprises or is a polyurethane adhesive or comprises. It is particularly preferred that the adhesive-containing layer (13) connects the laminate composite with a layer (15) consisting at least partially of a fiber-reinforced plastic.
• the epoxy adhesive or the polyurethane adhesive is set to thixotropic before curing.
• the adhesive can also fill gaps of several millimeters thickness before curing.
• the layer (15) is a fiber-reinforced plastic (FRP), a plastic reinforced by means of UHMW-PE fibers (eg Dyneema fibers), a carbon fiber reinforced plastic (CFRP ) or a glass fiber reinforced plastic (GRP) is, preferably a glass fiber reinforced plastic (GRP) is.
• FRP fiber-reinforced plastic
• CFRP carbon fiber reinforced plastic
• GRP glass fiber reinforced plastic
• the layer (15) is a plastic resin system with an epoxy resin matrix, polyurethane resin matrix, poly (meth) acrylate matrix, polymethyl (meth) acrylate matrix or poly (meth) acrylamide matrix, in particular preferably is a plastic resin system with an epoxy resin matrix.
• the layer (13) has a thickness of 1 to 5,000 ⁇ , preferably has a thickness of 5 to 4,000 ⁇ , more preferably a thickness of 10 to 3,000 ⁇ .
• a wind turbine comprising a composite component according to the invention. It is particularly preferred that it is a wind turbine of a wind turbine and the composite component according to the invention is arranged on at least one rotor blade element, in particular on at least one rotor blade edge, preferably a rotor blade leading edge. It is particularly preferred that the composite component according to the invention is arranged on all rotor blade edges, preferably on all rotor blade leading edges, of a wind energy plant.
• FIG. 1 Another aspect in the context of the present invention relates to a use of the plastic composite component according to the invention in wind turbines.
• Particularly preferred is the use according to the invention in rotor blade edges, preferably at rotor blade front ends, of a wind energy plant.
• the composite component according to the invention can also be used in other areas in which erosion of the surfaces should be avoided. These are for example according to the invention:
• Turbine blades of engines • bodywork components of vehicles,
• Another aspect in connection with the present invention relates to a method for producing a composite component according to the invention. comprising the following steps:
• the polyurethane of the layer (12) is a thermoplastic polyurethane and / or a polyurethane elastomer and / or the elastomer of the layer (12) is an ethylene-propylene rubber (EPM), ethylene-propylene Diene rubber (EPDM), ethylene-acrylate rubber (EA), fluorocarbon rubber (FKM), acrylate rubber (ACM) or acrylonitrile-butadiene rubber (NBR), preferably an ethylene-propylene-diene rubber (US Pat. EPDM).
• EPM ethylene-propylene rubber
• EPDM ethylene-propylene Diene rubber
• EA ethylene-acrylate rubber
• FKM fluorocarbon rubber
• ACM acrylate rubber
• NBR acrylonitrile-butadiene rubber
• the polyethylene of the layer (11) is a High Molecular Polyethylene (HMW-PE), an Ultra High Molecular Polyethylene (UHMW-PE) or Polytetrafluoroethylene (PTFE), preferably an Ultra High Molecular Polyethylene ( UHMW-PE).
• HMW-PE High Molecular Polyethylene
• UHMW-PE Ultra High Molecular Polyethylene
• PTFE Polytetrafluoroethylene
• the elastomer of the layer (12) is a polyurethane (preferably thermoplastic polyurethane and / or polyurethane elastomer) and the polyethylene of the layer (1 1) Ultra High Molecular Polyethylene (UHMW-PE).
• the elastomer of the layer (12) is an ethylene-propylene-diene rubber (EPDM) and the polyethylene of the layer (1 1) Ultra High Molecular Polyethylene (UHMW-PE).
• the method according to the invention is in the means of fibers (14) reinforced plastic of the layer (13) by means of UHMW-PE fibers (eg Dyneema fibers) reinforced plastic, a Carbon fiber reinforced plastic (CFRP) or a glass fiber reinforced plastic (GRP), preferably a glass fiber reinforced plastic (GRP).
• UHMW-PE fibers eg Dyneema fibers
• CFRP Carbon fiber reinforced plastic
• GRP glass fiber reinforced plastic
• GRP glass fiber reinforced plastic
• the polyurethane of the layer (12) is a thermoplastic polyurethane and / or polyurethane elastomer and the polyethylene of the layer (1 1) is an Ultra High Molecular Polyethylene (UHMW-PE) and the by means of fibers (14) reinforced plastic of the layer (13) is a glass fiber reinforced plastic (GRP).
• UHMW-PE Ultra High Molecular Polyethylene
• GRP glass fiber reinforced plastic
• the uncured layer (13) is an epoxy resin, preferably a two-component epoxy resin, which is mixed with the prepared or provided laminate composite prior to assembly.
• the layer (11) and / or layer (12) was pretreated to produce a laminate composite containing layers (11) and (12), preferably by one, two, three or more of the pretreatment methods selected from the group comprising
• thermal surface treatment in particular plasma activation, plasma surface treatment and gas flame treatment
• the laminate composite containing layers (11) and (12) is pretreated with a non-hardened layer (13) after production or provision and before joining the produced or provided laminate composite, preferably by two, three or more of the pretreatment methods selected from the group comprising
• thermal surface treatment in particular plasma activation, plasma surface treatment and gas flame treatment
• pretreatment of the laminates comprising the layers (1 1) and (12) is preferably carried out on the layer (12).
• the joining of the layer (13) to the layers (1 1) and (12) comprising laminate composite under heat preferably at temperatures of at least 20 ° C, preferably of at least 35 ° C, more preferably of at least 55 ° C, more preferably of at least 75 ° C instead.
• the joining of the layer (13) on the layers (1 1) and (12) comprising laminate composite under heat preferably at temperatures of at most 120 ° C, preferably of at most 1 10 ° C, on preferably of not more than 95 ° C, more preferably of not more than 85 ° C instead.
• the joining of the layer (13) to the laminates comprising the layers (1 1) and (12) takes place under the action of heat, preferably at temperatures of 20 to 120 ° C, particularly preferably at temperatures of 35 to 1 10 ° C, more preferably at Temperatures of 55 to 95 ° C and most preferably at temperatures of 75
• Another aspect in the context of the present invention relates to a composite component produced by a method according to the invention.
• a further aspect in connection with the present invention relates to a method for repairing and / or repairing a rotor plate (in the context of this application likewise a production method, see above), preferably of a rotor blade element of a wind energy plant with a wind turbine according to the invention
• Composite component comprising the following steps: - preparing the damaged rotor blade element,
• a method according to the invention is preferred in which the preparation of the damaged rotor blade element comprises at least one of the following steps:
• thermal surface treatment in particular plasma activation, plasma surface treatment and gas flame treatment
• FIG. 1 shows a schematic representation of a wind energy plant with rotor blade element according to the invention:
• Fig. 2 shows schematically an embodiment of a rotor blade element according to the invention:
• Fig. 3 shows a schematic representation of a section of the rotor blade element of Fig. 2;
• Fig. 4 shows a schematic representation of an alternative section of the rotor blade element.
• FIG. 1 shows a wind energy plant 1000 with a tower 1200 and a gondola 1300.
• a rotor 1400 with three rotor blades 1 100 and a spinner 1500 is arranged on the nacelle 1300.
• the rotor 1400 is rotated by the wind in operation and thereby drives a generator in the nacelle 1300.
• the rotor blades 1 100 of the wind energy plant 1000 have a base (layer 13) made of a plastic reinforced at least partially by fibers and are in places coated with a surface film (layer 1 1) made of polyethylene, wherein between the Oberflä- chenfolie and the base a polyurethane layer or elastomer layer (layer 12) is located.
• This structure will be explained in more detail with reference to the following figures.
• Fig. 2 shows a rotor blade element 1 1 10 of the rotor blade 1 100, namely the rotor blade nose.
• the rotor blade nose 1 1 10 has a surface foil 1 1.
• This consists in this embodiment of ultra high molecular weight polyethylene (UHMW-PE).
• the surface film 1 1 (layer 11) is connected via a bonding layer 12 (layer 12) to the base of the rotor blade element 13 (layer 13).
• the base 13 (layer 13) of the rotor blade element consists at least partially of a reinforced by means of fibers (14) plastic.
• the fiber material is glass fiber reinforced plastic (GRP) and the curable resin is an epoxy resin.
• the bonding layer 12 (layer 12) consists at least partially of a polyurethane and / or an elastomer.
• the surface film 1 1 (layer 1 1) is particularly resistant to abrasive loads such as those that occur when operating wind turbines, in particular at the rotor edges.
• a first layer (1 1) which consists at least partially of polyethylene, a layer (12) at least partially made of a polyurethane and / or an elastomer, and at least one layer (13) as a base, which consists at least partially of a plastic reinforced by fibers (14).
• the fiber material is glass fiber reinforced plastic (GRP) and the curable resin is an epoxy resin
• the polyethylene is an ultra-high molecular weight polyethylene (UHMW-PE)
• UHMW-PE ultra-high molecular weight polyethylene
• EPDM ethylene-propylene diene Rubber
• Fig. 4 shows an alternative section of the rotor blade element 1 1 10.
• the rotor blade element 1 1 10 has the following layer structure: A first layer (1 1), which consists at least partially of polyethylene, a layer (12 ), which consists at least partially of a polyurethane and / or an elastomer, at least one layer (13) which consists at least partially of an adhesive and a layer (15) which consists at least partially of a reinforced plastic by means of fibers (14).
• the fiber material is glass fiber reinforced plastic (GRP) and the curable resin is an epoxy resin
• the polyethylene is an ultra-high molecular weight polyethylene (UHMW-PE).
• the polyurethane may be a thermoplastic polyurethane elastomer, a thermoplastic polyurethane or a polyurethane elastomer or the elastomer is an ethylene-propylene-diene rubber (EPDM) and the adhesive is an epoxy resin adhesive.
• EPDM ethylene-propylene-diene rubber

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• 2016
  • 2016-10-21 ES ES16784914T patent/ES2741277T5/es active Active
  • 2016-10-21 EP EP16784914.0A patent/EP3365166B2/de active Active
  • 2016-10-21 DK DK16784914.0T patent/DK3365166T4/da active
  • 2016-10-21 CA CA3002485A patent/CA3002485C/en active Active
  • 2016-10-21 WO PCT/EP2016/075448 patent/WO2017068152A1/de active Application Filing
  • 2016-10-21 US US15/769,978 patent/US20180304605A1/en not_active Abandoned
  • 2016-10-21 BR BR112018007902-2A patent/BR112018007902B1/pt active IP Right Grant
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• 2020
  • 2020-11-02 US US17/087,272 patent/US20210070026A1/en not_active Abandoned
• 2022
  • 2022-06-02 US US17/831,314 patent/US20230125200A1/en active Pending

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